KR100648020B1 - Articles and methods for applying color on surfaces - Google Patents

Abstract

An article 10 for applying color on a surface comprises a dry color component sheet 12 having an edge, a sheet front side and a sheet back side opposite the sheet front side; Adhesive 25 on the back of the sheet for bonding the sheet to the surface. The edge of the sheet or the entire sheet is intended to reduce the visible perception of the seam produced when the edge is placed in overlapping, abutting or spaced relationship with the edge of the juxtaposed second article. The reduction or removal of visible perception of the seam may be enhanced by physical, chemical, optical, or a combination of these mechanisms.

Description

ARTICLES AND METHODS FOR APPLYING COLOR ON SURFACES}

The present invention relates to articles and methods for applying color, in particular articles and methods for applying a dry colorant to a surface.

It is often desirable to apply one or more colors for aesthetic advantages and / or functional advantages such as waterproofing on a surface, for example an architectural surface such as an interior wall or exterior wall. The color is typically provided by conventional painting or application of wallpaper with aqueous or oily wet paint, and the like. The hard processes involved in wet painting and papering are well known. Typically, during this activity, it is necessary to protect the surrounding area from secondary contamination, such as by applying a tape to adjacent surfaces where color is not required and by placing a paint cloth to protect the floor and furniture. In addition, extreme care must be taken to avoid dripping paint, wallpaper paste or primer, or other wet applied materials. In addition, many wet paint and wallpaper products are recommended to be used with one or more priming materials to aid in the coating and / or durability of the required color, whereby time and effort to produce the required color effect on such surfaces. Is increased.

In addition, it is typically necessary to soak a brush, roller, or other applicator with paint, primed material, or glue to apply material to the surface. As a result, a significant amount of material is wasted because the material does not reach the intended surface and remains on the applicator. It is also time consuming to clean brushes, sprayers, rollers and other tools used for the application of wet paint and wallpaper when the painting or paperwork is completed once or at least for a period of time, such as overnight pauses.

Many paints suitable for application to surfaces such as building surfaces include one or more volatile organic components. Such paints release toxic gases during and after application, requiring ventilation during and after application, particularly in closed environments such as buildings.

In structural surface coating operations requiring multiple strips of material or sheets, seams are formed between each juxtaposed strip pair. Seams provide defects that degrade the aesthetic appearance or some other characteristic of the appearance provided by the strips. As a result, seam concealment is an important concern in this structural surface coating operation. For example, seams between adjacent gypsum board panels are covered with gypsum board tape. Regarding the coating operation of applying color to the surface, the wallpaper is applied to the inner wall by attaching a plurality of strips adjacent to each other. The wallpaper can be applied systematically to the inner wall by aligning the vertical edges of the original strip with plumb lines drawn on the wall. At least one of the opposing vertical edges of the original strip serves as a vertical guide for the application of the subsequent strip of wallpaper. Adjacent strips of the strips are positioned in contact to minimize the presence of or gaps between the juxtaposed edges. Typically, however, vertical seams between adjacent strip pairs are visually perceived. The visual presence of the vertical seam degrades the aesthetic appearance of the color applied to the surface by the wallpaper.

Thus, despite the apparent aesthetic and / or functional benefits provided by applying color on the surface by conventional techniques such as wet painting or wallpapering, the effort required in connection with this procedure is inconvenient, time consuming, and furthermore, The color applied to the surface may include one or more seams that degrade the development of color effects on the viewer.

The present invention relates to an article for applying color on a surface, the article comprising a dry colorant sheet having a peripheral edge, a margin adjacent to the peripheral edge, a sheet front side and a sheet back side opposite the sheet front side; ; Adhesive on the back for bonding the sheet to the surface. The sheet has a thickness of less than 76 μm (3.0 mil). In various embodiments of the present invention, the edges of the sheets, or the entire sheet including the edges, are intended to reduce the visible perception generated when two sheets are placed in a juxtaposed relationship.

Various advantages, objects and features of the present invention will become more readily apparent to those skilled in the art upon reviewing the following detailed description of the preferred embodiments taken in conjunction with the accompanying drawings.

1 is a schematic plan view of an article for applying color to a surface according to the present invention;

2 is a schematic end view of the article of FIG. 1.

3 is a schematic end view of two articles as in FIG. 1 applied in a juxtaposition relationship to a surface such that a gap is formed between the articles;

4 is a transverse end view of a filler strip constructed in accordance with the principles of the present invention for filling gaps between adjacent articles as shown in FIG.

5 is a schematic end view of a juxtaposed article pair with overlapping edges.

6 is a schematic end view similar to FIG. 5;

7 is a schematic end view of a thinned article, in accordance with the principles of the present invention;

8 is a schematic end view of a thinned article, in accordance with the principles of the present invention;

9A and 9B are schematic cross-sectional views of thinned articles, in accordance with the principles of the present invention;

10 is a schematic cross-sectional view of a portion of an article having particulates, in accordance with the principles of the present invention.

11 is a schematic end view of a portion of an article having protrusions in accordance with the principles of the present invention.

12 is a schematic cross-sectional view of a portion of an article having a cellular structure, in accordance with the principles of the present invention.

13 is a schematic representation of a portion of an article having a contoured outer edge, in accordance with the principles of the present invention.

14 is a schematic representation of a portion of an article having a pattern, in accordance with the principles of the present invention.

15 is a schematic cross-sectional view of a portion of an article having three-dimensional topography, in accordance with the principles of the present invention.

16 is a schematic diagram of one process for making an article for applying color on a surface, in accordance with the principles of the present invention;

The present invention relates to articles and methods for applying color on a surface. As employed herein, the term "color" is used to refer to a color effect, that is, a difference in color or color recognition. In a specific embodiment, the color effect is in fact a permanent color effect, i.e. a color effect that is not removed in the case of routine contact or light cleaning. Thus, in effect, permanent color effects are distinguished from temporary color effects that are easily removed or reduced, such as those provided by chalk or crayons. The terms "colorant" and color component are used herein synonymously to refer to the components of the article of the present invention that provide a color effect. Specifically, the colorant is any composition that provides an opaque coating to the surface to which the colorant is applied, and generally the colorant comprises a dry pigment or dye, alone or in combination with additional components. For example, the colorant may be a dry paint comprising pigment particles, other conventional paint components, and a liquid carrier substantially removed by evaporation during the process of providing the dry paint.

As another example, the colorant may be an industrial sheet or laminate containing materials such as pigment particles or dye molecules in a concentration and suitable distribution sufficient to provide a color effect and formed from a suitable thermoplastic resin. Specifically, the colorant may be formed from thermoforming industrial polymeric resins including, but not limited to, acrylic, urethane, polyvinyl chloride (PVC), polyvinylidene fluoride (PVDF) and polyvinylidene chloride (PVDC). . The various layers of colorant may have different compositions and / or properties that are effective for applying color to the surface.

 The term surface is used herein to refer to any outer layer or boundary of an object or substrate capable of receiving a color component thereon. Suitable surfaces may be substantially two-dimensional and flat, or substantially three-dimensional and include curved or angled portions, and the like. In one embodiment, surfaces to which color components are applied using the articles and methods of the present invention include architectural surfaces, ie, surfaces of buildings, fixtures (ie, fixtures) of furniture, furniture, and the like. An architectural building surface may be an interior surface within a building or an exterior surface on the exterior of a building. Architectural surfaces that are substantially three-dimensional may include, for example, corner treatments of two-dimensional surfaces such as moldings (eg, moldings around windows or doorways), floorboards, fixtures, furniture, and the like. The building surface may be permanently installed, temporarily installed or movable. In addition, the articles of the present invention may be applied to the surface of an article to provide a texture and / or appearance that is the same or different than the building surface. For example, the products of the present invention can be used to apply color layers to fixtures, furniture, and other building supplies. Additional surfaces suitable for application of color using the articles and methods of the present invention will become apparent to those skilled in the art by the description herein.

1 and 2, an article 10 for applying color onto a surface (not shown), according to the present invention, comprises a flat sheet 12 of a dry colorant or dry color component, an adhesive or a binder. Layer 25. The seat 12 has a seat front 14, a seat back 16 opposite the seat front 14, four outer edges 20, 22, 24, 26, and outer corners 20, 22, 24, 26. ) And an edge 18 disposed adjacent thereto. The edge 18 is an annular strip of dry colorant extending circumferentially about the outer circumferential edges 20, 22, 24, 26 of the sheet 12 and inward toward the center of the sheet 12 by a predetermined dimension or width, or Define the band. An example of article 10 is an agent control number 8817P, filed December 20, 2001, and entitled United States entitled "Articles and Methods for Applying Color on Surfaces." Provisional Patent Application No. 60 / 343,146, Agent Control No. 8817P2, filed May 13, 2002, entitled U.S. Provisional Patent Application No. 60 / 380,225, entitled "Goods and Methods for Applying Color on Surfaces"; And U.S. Provisional Application No. 60 / 380,205, filed May 13, 2002, as agent control number 8817P3, entitled "Goods and Methods for Applying Color on Surface". Each of these applications is hereby incorporated by reference in its entirety. The article 10 may be a laminate formed from multiple layers of thermoplastic resin, as indicated at 19 in FIG. 2 and shown in dashed lines. In general, the average thickness of the sheet 12 and adhesive layer 25 is about 76 μm (3 mil) or less.                 

The adhesive layer 25 is applied to a substantial portion of the sheet backside 16 of the sheet 12. The adhesive layer 25 may be any adhesive that acts to create a secure adhesive bond between the article 10 and the surface (not shown). Particularly suitable adhesives are pressure sensitive adhesives that allow the article 10 to be secured to the surface and to allow the article to be repositioned before applying a pressure of sufficient magnitude to create a final adhesive bond with the surface. The article 10 may be wound into a roll and applied to the surface by a suitable application device (not shown) that operates to dispense the article 10 in a controlled manner. Alternatively, article 10 may be applied to a surface without the use of an application device. It will be appreciated that the application device may facilitate or otherwise implement certain embodiments of the present invention to remove, reduce or otherwise mitigate the visible perception of seams between adjacent pairs of articles 10.

As the dimensions of the article 10 are limited, a number of articles 10 are placed in an adjacent or juxtaposed relationship to apply color to certain surfaces, such as architectural surfaces, including interior and exterior walls of residential and commercial buildings. As a result, one of the outer peripheral edges 20, 22, 24, 26 of the sheet 12 is positioned adjacent to one of the outer peripheral edges 20, 22, 24, 26 of the other adjacent sheet 12. Depending on the precise placement of the sheets 12, each edge 18 of the juxtaposed pair of sheets 12 overlaps, abuts, or is separated or spaced by a groove or gap to create a seam. Seams exhibit irregularities in the smooth, uninterrupted coating that otherwise would otherwise form the article on the surface.

Seams tend to be visually recognized or identified by the observer and, if not corrected, degrade the aesthetic appearance of the color provided to the surface by the article 10. In accordance with the principles of the present invention, the visible perception of the seam may be alleviated, reduced or eliminated by modifying one or more characteristics or features of the article 10. Changes in the visible perception of the seam may be facilitated by physical, chemical, optical, or a combination thereof.

Adjacent articles 10 may overlap or create a gap, for example, due to inaccuracies during application to the surface. Overlaps or gaps between adjacent articles 10 may be introduced due to dimensional irregularities in the surface to which the articles 10 are applied. For example, the building surface may be curved inwards and outwards, may be tilted, skewed, and often the inner and outer corners may not be vertical. Moreover, features such as windows and doors that exist on most architectural surfaces are often not vertical and sometimes quite so, and ceiling lines can be unevenly tilted or inclined. Such irregularities can be caused by the arrangement of structural elements of the building or by construction errors. Overlapping also exists when an article of custom dimensions is used to patch existing color effects on a surface, for example to cover a small area from which the original color has been removed, or to cover or hide a mark.

Referring to FIG. 3, with some dimensions exaggerated for illustration, a gap or groove 30 between each pair of articles 10 juxtaposed, for example two articles 10 are applied to a surface 28. Is generated. The adhesive layer 25 of each article 10 contacts the opposite portions of the surface 28 to facilitate adhesive bonding therebetween. When article 10 is applied to surface 28, edge 18 of one sheet 12 is juxtaposed in parallel with edge 18 of adjacent sheet 12 to create groove 30. . The grooves 30 may have a uniform width or varying width and may be linear or nonlinear along the range of juxtapositions.

In accordance with the principles of the present invention, a filler may be introduced into the groove 30 after the article 10 is applied to the surface 28. The filler material can have any suitable structure or form with one or more properties that can reduce the visible perception of the groove 30.

In one embodiment, the filler is a grout 31 composed of a dispersible material having a moderately low viscosity that enhances physical properties at ambient temperature, such as spreadability, suitable to be accommodated in the groove 30. The grout 31 may be any material having visible properties similar to the visible properties of the sheet 12 of adjacent articles 10 after application and curing, and preferably the sheet 12 of adjacent articles 10. ) May be any material that is indistinguishable or indistinguishable in the visible appearance. For this purpose, the grout 31 may comprise a polymer or resin similar to the polymer or resin forming the base material of the sheet 12 or the base material of at least one layer of the sheet 12 being laminated. Grout 31 typically includes materials such as pigments or dyes that serve to provide the desired visible properties, and suitable solvents or other dispersants. After the grout 31 is received in the groove 30, a portion of the dispersant preferably evaporates over a characteristic curing time where the viscosity of the grout 31 is significantly reduced, among others.                 

The present invention contemplates that the grout 31 may be applied manually to the groove 30 between the juxtaposed articles 10 or with the aid of an application device (not shown). Specifically, for manual application, the grout 31 is introduced or injected into the groove 30 and wiped or treated with a trowel to remove any excess, such that the remaining grout 31 is removed from the sheet 12. It is generally coplanar with each seat face 14. Applicable devices suitable for use in this aspect of the invention include a reservoir that is rechargeable and contains a predetermined amount of grout 31, a dispensing element that introduces grout 31 into groove 30 at a controlled, constant rate, and groove ( A trowel or wiping element for removing any excess grout 31 not received within 30).

In another embodiment of the present invention and with reference to FIG. 4, other suitable filler in accordance with the present invention may be combined with the groove 30 in a manner that eliminates, reduces or mitigates the visible perception of the groove 30. The filler strip 32 in the form of. As shown, the filler strip 32 includes a central portion 34 and opposing thin flexible edges 36, 38 located on the side of the central portion 34. The central portion 34 is at least partially received in the groove 30 with each edge 36, 38 overlapping a corresponding one of the edges 18 of the two sheets 12. In one embodiment, central portion 34 is rigid, and edges 36 and 38 are compliant or flexible. Desirably, the filler strip 32 substantially fills the grooves 30 in a manner that withstands significant removal force after application. As shown, the thickness of the edges 36, 38 is smaller than the thickness of each sheet 12 such that the edges 36, 38 add a minimum incremental thickness to the total thickness of adjacent articles 10. Alternatively, the edges 36, 38 of the filler strip 32 may be optically transparent or translucent so that the color provided by the sheet 12 can be seen through the filler strip.

5 and 6 with some exaggerated dimensions for explanation, the edges adjacent to one of the outer circumferential edges 20, 22, 24, 26 of one sheet 12 in order to impart color on the surface. Multiple articles 10 may be applied such that 18 has an overlapping relationship with the edge 18 adjacent to one of the outer peripheral edges 20, 22, 24, 26 of the other sheet 12. As shown in FIGS. 5 and 6, a portion of the edge 18 of the seat 12 located at the top provides an upper seam 44 with an exposed surface visible to the viewer, and is placed at the bottom. A portion of the edge 18 of the sheet 12 is captured as an underseam 46 between the upper seam 44 and the surface 28. Typically, the overlap between the upper seam 44 and the lower seam 46 will be about 12.7 mm (0.5 inch) or less, but the present invention indicates that the overlap between the articles 10 extends over the entire area of the sheet 12. Is not limited thereto. The average thickness of the overlapped top seam 44 and bottom seam 46 is less than about 0.15 mm (6 mil). Overall, the upper seam 44 and the lower seam 46 form a seam that may be visually perceived by an observer of the color effect provided on the surface 28 if not corrected in accordance with one or more embodiments of the present invention. .

5 and 6, the upper seam 44 and the lower seam 46 can be characterized in three dimensions by height in the z direction, width in the x direction, and length in the y direction. That the seam formed by the upper seam 44 and the lower seam 46 extends in the y direction into the planes of the pages of FIGS. 5 and 6 and that the effective dimension of the seam in the x direction typically varies in the y direction. It is understood. The incremental height added by the upper seam 44 in the z direction is substantially the same as the thickness of the edge 18. A portion of the seam may have a non-contact relationship with surface 28 such that a cavity 48 is created between a portion of edge 18 and surface 28. The other portion of the upper seam 44 creates a steep edge cut off at the outer circumferential edge 24. Discontinuities in the substantially flat surface of juxtaposed articles 10, introduced by the presence of edges 24, provide an observer of surface 28 with an observable or perceptible visual indication of the location of edges 24. .

According to the principles of the present invention, at least the edge 18 of the sheet 12 adjacent to the outer circumferential edge of at least one of the entire sheet 12 or the outer circumferential edges 20, 22, 24, 26 is a juxtaposed sheet 12. It is modified in such a way as to eliminate, reduce or mitigate the visible perception of the upper seam 44 created by the overlap between each edge 18 of the pair. It is contemplated that various principles of the present invention may be combined to achieve removal, reduction, or mitigation of the visible perception of the seams provided by the upper seam 44 and the lower seam 46.

In one embodiment of the invention, the edge 18 adjacent to at least one of the outer peripheral edges 20, 22, 24, 26 is laterally disposed between the edges 18 before being applied to the surface 28. It is thin compared to the other parts of the sheet 12 which has been made. Typically, the average thickness of the edge 18 adjacent to at least one of the outer peripheral edges 20, 22, 24, 26 is approximately equal to the thickness of the remaining portion of the dry colorant sheet so that the composite thickness of the sheet is uniform or substantially uniform after overlapping. It may be reduced by half. However, the present invention is not limited thereto. All areas of the article 10, including the superimposed upper seam 44 and the lower seam 46 when the edge 18 overlaps the edge 18 of the other sheet 12, are entitled "reflection (spectrometer). Have an opacity index in the range of about 0.95 to 1.0 as measured according to ASTM D2805, Standard Test Method for Hiding Power of Paints by Reflectometry (Spectrometer). do.

Referring to FIG. 7 and according to one specific embodiment of the present invention where the edge is thinned, the edge 18 of the sheet 12 is inclined or tapered outward toward the outer peripheral edges 20, 24. It is understood that the edge adjacent to any of the outer peripheral edges 20, 22, 24, 26 can also be tapered. As shown in FIG. 7, the edges 18 taper towards the seat front 14 toward the outer circumferential edge 20 and toward the seat back 16 near the outer circumferential edge 24. The tapering of the edge 18 provides oppositely oriented wedge shaped surfaces 40, 42 extending into and out of the plane of the page of FIG. 7. Specifically, the edge 18 has a reduced second thickness at each circumferential edge 20, 24 from a first thickness at each common boundary 41, 43 shared with the outer circumferential inner portion of the sheet 12. Tapered to As a result, the thickness of the edge 18 decreases in the direction from each common boundary 41, 43 to the corresponding outer edge of the outer edges 20, 24. It is understood that the edge 18 may taper at non-uniform taper angles such that the thickness of the wedge-shaped surfaces 40, 42 does not monotonically change as shown in FIG. 7. For example, the edge 18 adjacent to at least one of the outer circumferential edges 20, 22, 24, 26 may cause the thickness of the thinning portion in the z direction and the transverse width in the x direction to vary arbitrarily depending on the position. It may be cut off.

In another specific embodiment where the edges are thinned and with reference to FIG. 8, the edge 18 of the sheet 12 is a joint half 45 at the outer circumferential edge 20, and the opposite outer circumferential edge 24. Are formed as complementary joint halves 47. When the edge 18 of one article 10 overlaps and is secured by overlapping the edge 18 of the other article 10, the joint halves 45, 47 provide a complete lap joint. . Overlapping overlapping seams 45, 47 preferably have an effective thickness that creates a surface that is flush with the outer peripheral inner portion of each of the juxtaposed articles 10, or a continuous surface. It is understood that the joint halves 45, 47 can have any complementary structure that can be combined as overlapping joints and is not limited to the specific embodiment shown in FIG. 8.

7 and 8, the average thickness of the edge 18 shown in FIGS. 7 and 8 is less than the average thickness of the outer circumferential inner portion of the sheet 12. The present invention provides a mechanical or wet chemistry that selectively removes the appropriate thickness of the sheet 12, for example, by a molding process (eg, printing of the sheet 12) during or after the manufacture of the article 10. It is contemplated that the edge 18 can be thinned by providing the wedge shaped surfaces 40, 42 or the joint halves 45, 47 by the process. Alternatively, it is understood that mechanical and wet chemical thinning of the edge 18 may be performed at the time of applying the article 10 to the surface. Mechanical thinning processes generally rely on mechanical actions such as polishing or cutting for material removal, while wet chemical thinning processes generally rely on chemical reactions to etch, dissolve or otherwise remove materials. For chemical thinning, the thickness of the material to be removed may be controlled, for example, by adjusting the exposure time of the dry colorant at the edge 18 to the etchant compound. To this end, the etchant compound may be applied by a suitable application device and removed by a device such as a wet vacuum when the exposure time has elapsed, or by simply wiping with a suitable absorbent article or other removal device. The etchant compound may be provided to the consumer as a kit that also includes an article 10 for applying color, and an application and / or removal device for the etchant compound is provided on the surface 28 (FIG. 5). It is contemplated that it may be included in an authoring apparatus for applying 10).

With reference to FIG. 9A and in accordance with the principles of the present invention, the sheet 12 of the article 10 is formed of a plurality of, for example, five layers 50-54, to provide a stepped or rounded edge structure. Contouring at least at each of the peripheral edges 20, 24 effectively thins around the edge 18. For this purpose, the central layer 52 of the sheet 12 protrudes laterally outwardly beyond the layers 50, 51, 53, 54, and the layers 51, 53 transversely past the layers 50, 54. Project outward. The edge 18 of the juxtaposed article 10 pair, for example at the outer peripheral edge 20 of one of the articles 10, for example, the edge edge 24 of the other of the articles 10, may be used. When applied to the surface 28 (FIG. 5) in an overlapping state, the overlapping thickness of the upper seam 44 and the lower seam 46 will be significantly reduced due to the contact between the respective rounded corner structures. In addition, the step configuration of the edge 18 at the corners 20, 24 when viewed at a normal viewing distance from the surface 28 further eliminates, reduces or otherwise visually perceives the edges 20, 24. It provides a round appearance that acts to mitigate.

In an alternative embodiment and with reference to FIG. 9B, the sheet 12 of article 10 is formed from multiple, for example four layers 55-58, at least to provide a stepped or rounded edge structure. By contouring at each of the outer peripheral edges 20, 24, it is rounded around the edge 18. Specifically, the transverse outward protrusion of layers 55-58 may cause layer 58 from layer 55 to protrude outward with a minimum relative distance and layer 58 protrude outward with a maximum relative distance. Gradually decreases. Similar to the embodiment of the present invention shown in FIG. 9A, the pair of articles 10 has an edge 20 of one of the articles 10 and the other edge 24 of the other of the articles 10. When applied to surface 28 (FIG. 5) in an overlapping state, the overlap thickness will be significantly reduced. In addition, the step configuration of the edges 20, 24 when viewed by the viewer at a normal viewing distance from the surface 28 acts to further remove, reduce or otherwise mitigate the visible perception of the edges 20, 24. To provide a round appearance.

Edges 18 having one of the configurations shown in FIGS. 7, 8, 9A and 9B overlap the edges 18 of another juxtaposed article 10 which may have a complementary reduced thickness configuration. At that time, the average opacity index of the entire surface of the article 10 is between about 0.95 and 1.0 as measured according to ASTM D2805. The average thickness of the overlap of each edge 18 of the juxtaposed article 10 pair is less than 0.15 mm (6 mil).                 

According to another embodiment of the invention and referring again to FIGS. 1 and 2, the visible perception of the overlapping edges 18 of adjacent articles 10 acts to adjust the rheology of the sheet 12. Inclusion of additives eliminates, reduces or otherwise alleviates. The fluidization adjustment additive acts to promote selective coalescence, densification or fusion of the overlap of the edges 18 of the juxtaposed sheets 12. The action of the fluidization adjusting additive can occur spontaneously or with the aid of an initiator. In addition, a compression pressure may be applied to the edge 18 at the time of application without departing from the spirit and scope of the invention. The fluidization adjusting additive may be any chemical agent that temporarily increases the workability and flexibility of the sheet 12. The fluidization adjustment additive must be inert or otherwise at rest while the article 10 is stored and before being applied to the surface 28 (FIG. 5). The fluidization adjustment additive may volatilize or evaporate from the edge 18 after the characteristic working period, or may remain in the article 10 after the coalescence is complete. Once coalescing is complete, the fluidization adjustment additive should no longer be present or remain at a concentration such that the article 10 is not excessively affected by mechanical damage.

It is understood that the fluidization adjustment additive may be locally limited to the dry colorant forming the edges 18 or dispersed throughout the dry colorant forming the sheet 12. In either case, if it is desired to provide coalescence, the application of compression pressure can be limited to the edge 18 using suitable rollers of limited width or the like. It is also understood that the article 10 may need to be stored in a controlled environment after manufacture in order to preserve the chemical action of the volatile fluidization adjustment additive. For example, articles 10 containing such fluidization adjustment additives may be stored in a sealed container (not shown), such as a Mylar bag, after manufacture. The fluid impermeable wall of such a sealed container causes losses due to volatilization, evaporation or vaporization of the fluidization adjustment additive until the article 10 is unsealed from the container at the time of application to provide color to the surface 28 (FIG. 5). Prevent or otherwise inhibit. If the article 10 is only tightly wound, it is understood that any loss of fluidization adjustment additive due to volatilization is significantly reduced.

In some embodiments of the present invention, the fluidization adjusting additive may be a plasticizer added to the formulation of the material forming the sheet. The plasticizer will allow the dry colorant of the sheet 12 to flow for a period of time until the concentration of the temporary plasticizer is sufficiently reduced by volatilization. Typically, the plasticizer will be present at a concentration of less than about 30% by weight in the dry colorant of the sheet 12 after manufacture. Plasticizers suitable for use in the present invention include propylene glycol, ethylene glycol, dibutyl phthalate and tricresyl phosphate. Another plasticizer suitable for use in the present invention is benzyl phthalate, available under the trade name SANTICIZER® from Ferro Corporation (Cleveland, Ohio). In addition, the fluidization of the thermoplastic polymer used to form the article 10 can be modified, for example, by changing the type of thermoplastic resin, mixing various different polymer resins, or changing the molecular weight of the polymer.

In another embodiment of the present invention and continuing with reference to FIGS. 1 and 2, the fluidization adjustment additive may optionally be applied to a suitable initiator consisting of the active liquid at the time of application after the article 10 is applied to the surface 28 (FIG. 5). It is a liquid-sensitive chemical agent that acts to coalesce the edges 18 when exposed. The active liquid enhances the chemical reaction with the liquid-sensitive chemical agent that coalesces the dry colorant forming the edges 18, thereby reducing the thickness of the overlapping top seam 44 and the bottom seam 46 (FIG. 5). The exposed edges 24 of the upper seam 44 are rounded or curved. These two effects are believed to reduce the visible perception of the overlapping edges of the edges 18 of the juxtaposed article 10 pair.

The chemical reaction between the liquid-sensitive chemical agent and the active liquid reduces the desired thickness reduction of the upper seam 44 and the lower seam 46 and / or the rounding of the exposed edges of the upper seam 44 (FIG. 5). Is adjusted to provide. Preferably, after the desired reduction and / or rounding is achieved, the active liquid is consumed or exhausted to stop or otherwise stop the chemical reaction. Alternatively, the active liquid may be removed or a sufficient amount of suitable neutralizing agent may be added. Liquid-sensitive chemical agents and active liquids must be compatible with the chemical properties of the dry colorants forming the sheet 12 so that the physical properties and colors of the article 10 are not significantly affected when adhesion is induced and completed. The active liquid may be applied to the sheet 12 at ambient temperature or heated before application. It is understood that the liquid-sensitive chemical agent may be localized within the dry colorant forming the edges 18 or dispersed throughout the dry colorant forming the sheet 12. If the entire sheet 12 contains a liquid-sensitive chemical agent, the application of the active liquid should be adjusted to wet only the edge 18 as by employing a suitable application device of limited effective application width. The active liquid may be provided as a kit that also includes an article 10 for applying color, and an application device for the active solution may be included in the application device for applying the article 10 to the surface 28 (FIG. 5). This is considered.

In another embodiment of the present invention and with continued reference to FIGS. 1 and 2, the fluidization adjusting additive is a heat-active chemical agent that is activated when heated above ambient temperature at the time of application to the surface 28 (FIG. 5). . Heat-active chemical agents have a characteristic activation temperature that must be exceeded to initiate adhesion. Below the activation temperature, the heat-active chemical agent is inert or substantially inert. The activation temperature of the heat-active chemical agent is selected so that no significant physical degradation or color change will occur when the article 10 is heated to the activation temperature. This heat-active chemical agent is characterized by the fact that the overlapping top seam 44 and the dry colorant of the bottom seam 46 reduce the composite thickness and round the exposed outer edge 24 of the top seam 44 (FIG. 5). By spreading to make it more densely packed or flattened.

In order to initiate the coalescence, the edges 18 may reduce the required thickness reduction of the superimposed upper seam 44 and the lower seam 46 and / or the rounding of the outer circumferential edge 24 of the upper seam 44 (FIG. 5). It is exposed to a suitable heat source, for example a flow of hot air from a blower, a heated application device or roller, or a laser, for a period sufficient to produce and at a temperature. Optionally, a compression pressure may be applied to the edge 18 to aid in the action of the heat-active chemical agent. If the entire sheet 12 contains a heat-active chemical agent, the application of heat may be adjusted such that only the edge 18 is heated to the intrinsic active temperature. For example, heated rollers of suitable effective rolling width may be used. However, it is understood that the heat source can operate to transfer heat by convection, conduction, radiation, or a combination thereof.

The chemical properties of heat-active chemical agents should be compatible with the chemical properties of dry colorants so that the physical properties of the colorants are not significantly affected by the presence of heat-active compounds unless activated by heat. Exemplary heat-active chemical agents suitable for use in the present invention as copolymers include ethylene-vinyl acetate copolymers and polyvinyl acetate copolymers. Suitable ethylene-vinyl acetate resins are available under the trade name Ultrathen from Equistar (Houston, Texas). Suitable polyvinyl acetate resins are available under the trade name VINNAPAS® from Wacker Polymer Systems (Adrienne, Mich.). Generally, ethylene-vinyl acetate copolymers and polyvinyl acetate copolymers are known to have a softening range of about 50 ° C to about 125 ° C. It is contemplated that other suitable copolymers with different softening ranges for thermal activity may be selected depending on the particular application.

The sheet 12 formed of an industrial film containing a thermoplastic resin is easily deformed or placed in a state suitable for deformation by application of a compression pressure when heated to a sufficiently high temperature. As a result, fluidization control additives may be inherent in the formulation of the thermoplastic resin. For example, the base thermoplastic of sheet 12 may be mixed with other thermoplastics to provide the heat sensitivity necessary to induce adhesion.

It is contemplated that the fluidization adjustment additive may be contained within the microcapsule to release and activate upon application of an external trigger. Any suitable microencapsulation method may be used to divide the fluidization adjustment additive into fine liquid particles and to surround the particles of the fluidization adjustment additive with a rupturable skin wall formed of a material having a suitable composition. The material forming the skin wall should be of a material that is thick enough and / or suitably compatible to withstand chemical attack by the encapsulated fluidization control additive, and is preferably inert to the chemical action of the encapsulated fluidization control additive. At a minimum, the material of the skin wall should be impermeable to the restrained fluidization control additives for a sufficient shelf life after manufacture to allow the article 10 to be applied to the surface and to allow release of the fluidization adjustment additives. Particles of the microencapsulated fluidization adjustment additive may be evenly distributed in the sheet 12 at a uniform density, or may be confined to the edge 18.

One method of initiating the action of a microencapsulated chemical agent provides a fragile skin wall that is thin enough to rupture during mechanical or physical manipulation, such as compression pressure, during or immediately after application of article 10 to surface 28. It is. The envelope wall should have a thickness sufficient to prevent premature release of the chemical agent by unintentional rupture during physical manipulations that occur during mixing and sheet making and during storage. Other triggers for initiation or activation include, but are not limited to, release by dissolving the envelope wall with a suitable solvent, and by selectively exposing the envelope wall to radiant energy such as heat or light.

In another embodiment of the present invention and with continued reference to FIGS. 1 and 2, the fluidization adjustment additive is a solvent that acts to coalesce the dry colorant of the edge 18 at the time of application. Such solvents may reduce the thickness of the superimposed upper seam 44 and the lower seam 46 (FIG. 5) and allow the exposed edges 24 of the upper seam 44 (FIG. 5) to be rounded or curved to form a dry colorant. Enhances the chemical reaction with the dry colorants forming the edges 18, which coalesce the polymer or resin base material. The action of the solvent is adjusted to provide the required degree of thickness reduction and / or rounding levels. The solvent should be compatible with the formulation of the dry colorant so that the physical properties and colors of the article 10 are not permanently significantly affected after the adhesion is complete. Application of the solvent is preferably adjusted such that only the edge 18 is wet. For the sheet 12 formed of the thermoplastic resin, suitable solvents include, but are not limited to, toluene, methylethyl ketone, methyl isobutyl ketone, and ethanol.

In another embodiment of the present invention, the visible perception of the seams produced by the overlapping top seam 44 and the bottom seam 46 of each edge 18 (FIG. 5) is determined by the surface 28 (FIG. 5). Reduced by providing the article 10 (FIG. 5) at least near the edge 18 with an additive or structure that is mechanically compressed or collapsed upon application of a sufficient magnitude of compression pressure as an initiator after application of the article 10 to Removed. Generally, the magnitude of the compression pressure applied manually without mechanical assistance is less than about 345 kPa (50 PSI), and typically less than about 69 kPa (10 PSI). The compression pressure may be applied using a pressurization device such as a roller of a suitable width, which pressurizes the magnitude of the applied compression pressure by mechanical assistance, beyond the magnitude of the equivalent compression pressure applied to the pressurization device. Let's do it. It is understood that a suitable width may be the full width of the article 10. Selective collapse of the collapsible structure reduces the effective thickness of the upper seam 44 and the lower seam 46 after the juxtaposed article 10 pair is applied to the surface 28.

The compression pressure may be a differential pressure consisting of a first pressure applied to the edge 18 and a smaller pressure applied to the outer circumferential inner portion of the article 10. Alternatively, the compression pressure may be applied uniformly in such particular embodiments of the invention where the edge 18 is more susceptible to the effect of the compression pressure than the rest of the article 10. In the latter embodiments of the invention, the article 10 as a whole is modified such that its thickness is reduced by the application of compression pressure, and the edge 18 undergoes a greater thickness reduction compared to the outer circumferential inner portion of the article 10. To make the compression pressure more responsive. At the time of manufacture, the disintegrating structure or additive is introduced into the formulation of the dry colorant or into the formulation of the material forming the adhesive layer 25 (FIG. 5), or optionally provided by a suitable molding process at the time of manufacture.

In one specific embodiment of the present invention and with reference to FIG. 10, the article 10 is made to collapse or crush upon application of force at the time of application to the surface 28 (FIG. 5) and is typically gas filled. Of fine particles 60. The gas filled particulate 60 is contained in the dry colorant sheet 12 as shown in FIG. 10 or in the adhesive layer 25 as represented by the particulate 61 shown in phantom in FIG. It is understood that it may be included in all of these components of 10). It is understood that the microparticles 60, 61 may be positioned to span the boundary or interface between the dry colorant sheet 12 and the adhesive layer 25. The material forming the particulates 60, 61 and the gas filling the interior of the particulates 60, 61 should not be inert or otherwise react with the components of the sheet 12 and / or adhesive layer 25. Each of the gas filled particulates 60, 61 may be of any closed geometry, such as a spheroid.

Particles 60 and 61 may require that article 10 require a color effect. It should be small enough to not introduce outwardly extending protrusions that can be recognized by an observer looking at the sheet front 14 after being applied to the surface 28 (FIG. 5). Typically, the microparticles 60, 61 should have a particle size distribution in which the maximum dimension is less than about 75% of the thickness of the sheet 12 and the maximum particle size is less than about 75% of the thickness of the sheet 12. The microparticles 60, 61 may be uniformly dispersed throughout the volume of the sheet 12 and / or adhesive layer 25 (FIG. 5). If desired, any debris from the collapsed particulates 60, 61 is retained in the sheet 12 or adhesive layer 25.

In an alternative, it is understood that the inclusion of particulates 60, 61 in the dry colorant of sheet 12 and / or adhesive layer 25 (FIG. 5) may be limited to near edge 18. If the particulates 60, 61 are present only in the edge 18 (FIG. 5) or in the adhesive layer 25 below the edge 18, the overlap of the upper seam 44 and the lower seam 46 (FIG. 5) The thickness will be reduced by the application of compression pressure on them. If the particulates 60, 61 are present throughout the interior of the sheet 12, the overlapping top seam 44 and bottom seam 46 and / or adhesive layer 25 are more than other portions of the article 10. Differential compression pressure is applied at the time of application to receive a large compression pressure. The microspheres within the edge of the article 10 have a reduced survival rate under the action of differential pressure, such that the upper seam 44 and the lower seam 46 will become thinner than the rest of the sheet 12 as a whole. will be.

Each of the microparticles 60, 61 is thick and / or mechanically sufficient to withstand grinding or collapse until the article 10 is adhesively secured to the surface 28 (FIG. 5) until a compression pressure of sufficient magnitude is applied at the time of application. It has an outer wall 63 formed of any suitable material that is rigid. Particles 60, 61 formed from hollow glass spheriods are conventional and are apparent to those skilled in the art. Exemplary particulates 60, 61 in the form of hollow glass bubbles having a density ranging from 0.05 g / cm 3 to 0.10 g / cm 3 and a diameter ranging from 40 microns to 177 microns are described in US Pat. No. 6,194,064 (Keeley et al. ) Is disclosed. Industrial hollow glass microspheres of soda-lime-borosilicate glass compositions may be purchased from the Minnesota Mining and Manufacturing Company (St. Paul, Minn.) Under the tradename SCOTCHLITE® Glass Bubbles.

In an alternative embodiment and with reference to FIG. 11, the article 10 extends outwardly from the sheet back 16 toward the surface 28 when the sheet 12 is applied to the surface 28 (FIG. 5). It may also include a plurality of protrusions 62. The protrusion 62 is tapered, for example, from the base near the seat back 16 to the opposite tip and truncated conical with a circular, elliptical or polygonal cross section when viewed perpendicular to the seat back 16. Or a truncated conical protrusion. It is understood that the protrusion 62 may take other collapsible geometries such as semi-hemispherical shapes or long ridges without departing from the spirit and scope of the present invention. Adjacent protrusions of the protrusions 62 are spaced at appropriate intervals so that collapse of the adjacent protrusions of the protrusions 62 does not interfere. The protrusion 62 has a tensile strength that is susceptible to collapse or buckling along an axis substantially parallel to the surface normal of the surface 28 when a compressive pressure of sufficient magnitude is applied in a direction generally toward the surface 28.

In some embodiments, the protrusions 62 may be evenly distributed over the seat back 16, and the protrusions 62 in the edge 18 (FIG. 5) may be configured to collapse more easily. As a result, the application of a uniform compression pressure on the article 10 will provide the thinning and edge-rounding required for the upper seam 44 and the lower seam 46 (FIG. 5). In another embodiment of the present invention, the projection 62 is a differential compression consisting of a greater compression pressure applied to the superimposed upper seam 44 and the lower seam 46 relative to the compression pressure in other regions of the article 10. By selectively applying pressure, a uniform configuration and even greater thickness reduction can be achieved within the edge 18. In some more specific embodiments, the protrusions 62 may be provided only near the edge 18 of the sheet 12 such that the thickness reduction due to the collapsed protrusion 62 is limited to the edge 18.

In an alternative embodiment, the adhesive layer 25 (FIG. 5) is the sheet backside 16 of the sheet 12 in a pattern of protrusions comparable to the protrusion 62 which may collapse by the compression pressure applied at the time of application. It may be printed on (Fig. 5). When compression pressure is applied to promote collapse, sufficient space is provided between adjacent protrusions of the adhesive layer 25 so that the adhesive layer 25 expands.

In another alternative of the present invention and with reference to FIG. 12, a sheet 12 or a portion of the sheet 12 includes a cell comprising a plurality of cells 64 that may be open and interconnected or isolated and closed. Type structure is provided. Cell 64 easily collapses or buckles when a sufficient amount of compression pressure is applied in a direction generally towards surface 28 (FIG. 5). Typically, cells 64 include abutting rigid cell walls 65 that enclose a hollow inner cavity filled with a gas such as air. Each cell 64 has a larger dimension and / or weaker cell wall 65 at the edge 18 (FIG. 5) compared to each cell 64 in the outer circumferential inner portion of the sheet 12. As a result, it may collapse into a thinner final structure upon application of compression pressure as compared to the outer circumferential inner portion of the sheet 12. Alternatively, each cell 64 may have uniform ease of collapse and a differential pressure is applied during application to the surface such that the degree of collapse is greater at the edge 18 compared to the outer circumferential inner portion of the sheet 12. May be Alternatively, the cell-like structure may be provided only at the edge 18 such that only the thickness of the edge 18 of the sheet 12 is significantly changed by the application of compression pressure. In another embodiment and as shown in dashed lines in FIG. 12, the adhesive layer 25 is provided with a plurality of cells 67 constituting the cellular structure in addition to or in place of the cellular structure of the sheet 12. May be                 

In another embodiment of the present invention and with reference to FIG. 13, in which dimensions are enlarged for illustration, one or more outer peripheral edges 20, 22, 24 26 of the edge 18 of the sheet 12 are defined by a number of repeating elements. Contoured or molded into a pattern with 66. The repeating elements 66 include individual pattern components that collectively provide contoured edges 18, 22. The repeating element 66 has any configuration, arrangement, and / or dimensions that act to reduce the visible perception of the overlapping top seam 44 and the bottom seam 46 (FIG. 5). For monochromatic or almost monochromatic colors, the transitions between the repeating elements 66 and adjacent repeating elements of the repeating elements 66 are smoothly curved so that there are no sharp or jagged parts, but the present invention Is not limited to this. For articles 10 equipped with a patterned sheet front face 16 (FIG. 5), it has or has been edged with jagged edges in accordance with the principles of the present invention to be complementary to the printing pattern 68 (FIG. 14). Separate repeating elements 66 may be accommodated.

The repeating element 66 may be periodic with a constant frequency and amplitude, or may be aperiodic (ie, arbitrary) with varying irregular frequencies and amplitudes. Repetitive elements 66 having an amplitude and a wavelength of about 15 μm to about 12 mm are considered acceptable. The repeating element 66 may be created in the sheet 12 during the manufacturing process using any suitable apparatus that one of ordinary skill in the art would recognize, including but not limited to pattern shears and laser cutting Cutting mechanisms, such as an apparatus, are mentioned. Alternatively, repeating element 66 may be integrated, for example, by a hand-held tool or application device or into an application device used to apply article 10 to surface 28 (FIG. 5). It may be provided at the time of the application by the blade or cutter. The repeating element 66 changes the linear characteristics of the outer circumferential edge 24 of the upper seam 44 (FIG. 5). The perception of the upper seam 44 is reduced by the presence of the repeating element 66 because the human eye tends to perceive irregular edges less easily than linear edges.

In another embodiment of the present invention and with reference to FIG. 14, a printing pattern, indicated generally at 68, is provided on the sheet front face 14 of the sheet 12. The print pattern 68 includes various shaded areas or image elements 70 surrounded by contrasting areas 72. The image element 70 and the contrast area 72 may be configured to provide a visible perception of depth to the print pattern 68 or may be configured to provide a three dimensional appearance to the viewer. Alternatively, the printing pattern 68 may be equipped with three-dimensional actual depth or texture by using any printing technique known to those skilled in the art. Image element 70 and contrast area 72 may collectively form any geometrical shape or design that is effective to reduce the perception of overlapping edges 18. It is contemplated that the present invention may produce more complex print patterns 68 on the sheet front 14 by providing various different types of image elements 70 and / or various different types of contrast areas 72.

The print pattern 68 is applied on the sheet front 14 by applying any ink or dye composition that is solvent-based or water-based compatible with the dry colorant material forming the sheet 12. May be generated. Conventional methods of applying printing patterns include gravure printing, flexography, Mayer rod procedures, slot die applicators, roll coaters, and digital printing. Each of these is particularly suitable as it is useful for applying a printing pattern to sheet material that is conveyed past a printing station.

The dry colorant sheet 12 formed from the thermoplastic polymer resin may be provided with a print image by any suitable printing technique familiar to those skilled in the art. Moreover, the printed image formed on this sheet 12 has a relief that provides a textured appearance in addition to the unique pattern provided by the image element 70 and the contrast area 72. It may be.

The image elements 70 of the printed pattern 68 may be spaced at distances and frequencies that reduce the visible perception of the overlapping top seam 44 and the bottom seam 46 (FIG. 5). The image elements 70 that make up the print pattern 68 are typically constructed or arranged such that the print pattern 68 does not have tissue that is easily recognized and has any dimensions and spacing that do not conflict with seam concealment. Adjacent image elements of the image elements 70 in the print pattern 68 may have periodic two-dimensional spacings with long periodicity such that they are not easily recognized at a normal viewing distance. However, preferably, the image element 70 is any printed pattern 68 of the image elements 70, in which the organization, regularity, orientation or orientation of the image elements 70 which are components is not easily recognized. will be. In this amorphous or disordered pattern, the orientation and arrangement of one image element 70 relative to a neighboring image element 70 is relative to the orientation and arrangement of the next successive image elements 70 on the other side. It does not have predictable or known angles or spatial relationships.

In one specific embodiment of the invention, the print pattern 68 on the sheet front surface 14 may comprise a pixel matrix as will be appreciated by those skilled in the art. The print pattern 68 will have a predetermined pixel density measured in dots per inch. Each pixel in the print pattern 68 is characterized by a hue in the visible electromagnetic spectrum and a pixel size, typically in the range of about 30 μm to about 100 μm. The print pattern 68 of the pixels acts to apply the ink or dye composition onto the surface, and as understood by those skilled in the art, the sheet 12 may be formed by a suitable printing device such as a dot matrix printer, a laser printer or an inkjet printer. It may be printed on the sheet front face 14.

In another embodiment of the present invention and with reference to FIG. 15 where feature sizes are exaggerated for illustration, the sheet front face 14 (FIG. 2) of the sheet 12 may be cut into the sheet 12 or protrude outward from the sheet 12. Textured with three-dimensional topography consisting of a number of surface features 74. More specifically, surface features 74 are formed above and / or below the plane comprising the sheet front face 14 on a statistical average, and spatially distributed in a random fashion or in a repeating pattern. The profile of the surface features 74 can be of any shape or combination of these forms, for example, angular, curved, or irregular.

Surface features 74 may be added as an intentional or deliberate pattern that is aperiodic or amorphous, or that does not exhibit tissue that is not readily recognized. Preferably. The pattern of surface features 74 is amorphous in that surface features are not uniform in terms of their size, shape, orientation, and spacing between adjacent feature centers. In a completely amorphous pattern, as desired, the spacing between the centers of adjacent surface features 74 is the best for any surface feature 74 for any arbitrary angular orientation in the plane of the sheet 12. At least as specified by the designer is random within a limited area so that neighboring neighbors have the same probability of occurring.

One method of producing the surface features 74 is to add a number of fine particles, such as small particles of incompressible material such as sand or a deformable wax prill to the article 10. The fine particles may be located in the dry colorant of the sheet 12 or in the adhesive layer 25 (FIG. 5) applied to the sheet backside 16 of the sheet 12. The spatial distribution of the fine particles determines the topography of the dry colorant, which is preferably aperiodic or amorphous. The fine particles have a maximum dimension greater than the thickness of the article 10 and typically have a particle size range of about 0.15 μm to about 150 μm. After the article 10 is applied to the surface 28 (FIG. 5), the fine particles are visually perceived as protrusions projecting outwardly.

Alternatively, the textured pattern of surface features 74 may be stamped, imprinted, embossed or onto sheet 12 and / or using, for example, an embossing roller or stamp whose embossment represents the texture as a negative image. It may be stamped. Embossing may be accomplished by application of sufficient heat and / or sufficient pressure to impart a texture. The textured pattern of surface features 74 may be applied at the time of application or at the time of manufacture, or before or after the sheet 12 is installed on surface 28 (FIG. 5). Embossing an amorphous textured formed pattern on a flat article during manufacture is described in commonly owned US Pat. No. 6,193,918 (McGuire et al.), Which is incorporated herein by reference in its entirety. At the time of application, the textured pattern of surface features 74 may be heated and / or pressured using any suitable handheld tool, such as an embossing roller or, in its configuration, an application for an article 10 that includes an embossing roller. May be applied by

In another embodiment of the invention, a textured backing layer (not shown) may be combined with the sheet back surface 16 of the sheet 12 (FIG. 2) during manufacture or at the time of application. The textured backing layer can be any suitable material to which the stamped pattern can be delivered, such as paper and other cellulosic materials, polymeric films and woven or nonwoven fabrics, fabrics, glass or ceramic fabrics, and metallization layer (s). It may be formed as. Alternatively, the backing layer may be one layer of the laminate. The backing layer should exhibit sufficient flexibility to allow bending, rolling, and other similar manipulations of the article 10 during manufacture and at the time of application. In one specific embodiment, the textured backing sheet is separate from the sheet 12 and bonded to the article 10 at the time of application. To this end, the textured backing sheet is adhesively fixed to the surface 28 (FIG. 5), and the article 10 is adhesively bonded to the exposed surface of the textured backing sheet.

In another embodiment and with reference to FIGS. 1 and 2, the dry colorant forming edge 18 is adapted to transmit incident electromagnetic radiation having a wavelength in the visible region of the spectrum. The article 10 has an optically opaque edge 18 of one juxtaposed article 10 providing a lower seam 46 (FIG. 5) and an optically transmissive edge of the other juxtaposed article 10. 18 is applied to surface 28 (FIG. 5) with providing upper seam 44 (FIG. 5). In this case, the color of the edge 18 of the underlying juxtaposed sheet 12 will be visible through the optically transmissive edge 18 of the other juxtaposed sheet 12 overlying. The optically transmissive edge 18 may be a transparent medium having high light transmission such that incident electromagnetic radiation crosses the edge thickness with little interference such as absorption or reflection. It is understood that full optical transparency is not required, for which the edge 18 of the juxtaposed sheet 12 lying on top may be optically translucent so that the light reflected from the underlying opaque edge 18 diffuses. The present invention also contemplates that the entirety of the sheet 12 may transmit radiation having a wavelength in the visible region of the electromagnetic spectrum.

In another embodiment of the present invention, a light diffusing material may be added to the formulation of the dry colorant forming the sheet 12 (FIGS. 1 and 2). One specific light diffusing material is a pearlescent material that can produce pearlescent effects such as gloss, depth, iridescent, metallic luster, and multicolor glitter. Pearlescent materials include, but are not limited to, ethylene glycol distearate (EGDS), light diffusing microbeads, mica flakes coated with metal oxides, pearl essences obtained from fish scales or artificially produced, carbonic acid Lead, lead hydrogen arsenate, and bismuth oxychloride. Pearlescent materials produce color effects by interference, transmission and absorption of light. It is understood that the article 10 having the laminate structure may incorporate such light diffusing material into one or more separate layers. Furthermore and referring to FIGS. 9A and 9B, the light diffusing material may only be provided within the edge 18 of one of the visible layer edges of the laminate sheet 12, as shown in FIGS. 9A and 9B. It may be.

It is understood that the thickness of the dry colorant forming the sheet 12 will affect the perception of the seam formed by the overlapping top seam 44 and the bottom seam 46. Thus, thinning the dry colorant and adhesive layer 25 throughout the sheet 12 to a thickness of less than about 76 micrometers (3 mils) may reduce the visible perception of the seam.

The present invention provides for seam concealment where various attempts described herein are required to remove, reduce, or mitigate the perception of seams produced by superimposed top seam 44 and bottom seam 46 (FIG. 5). It is contemplated that combinations may be made without limitation. As a specific example, an attempt to provide a print pattern (FIG. 14) may be combined with an attempt to thin a dry colorant forming a sheet or edge (FIGS. 7 and 8) and an attempt to contour the outer peripheral edge of the edge (FIG. 13). Attempts to thin the dry colorant to form sheets or edges (FIGS. 7 and 8) may be used in combination with attempts to outline the outer peripheral edges of the edges (FIG. 13), and to form sheets or edges. Attempts to thin dry colorants (Figs. 7 and 8) may be used in combination with attempts to provide print patterns (Fig. 14), and attempts to thin dry colorants to form sheets or edges (Figs. 7 and 8). ) May be used in combination with an attempt to round the outer circumferential edge of the edge (FIGS. 9 and 9A) and thin the dry colorant forming the sheet or edge. Attempts (Figs. 7 and 8) may be used in combination with attempts to add light diffusing materials to the dry colorants, and attempts to thin the dry colorants forming the sheet or edge (Figs. 7 and 8) are surface features. It may be used in combination with an attempt to provide a texture with negative three-dimensional topography (FIG. 15), and an attempt to thin a dry colorant forming a sheet or edge (FIGS. 7 and 8) attempts to provide a collapsible structure. 10 and 11, and attempts to add fluidization control additives, such as heat-active chemical agents, to the dry colorant may attempt to provide a texture with three-dimensional topography of the surface features (FIG. 15). It can also be used in combination with).

It is also understood that the seam formed collectively by the superimposed upper seam 44 and the lower seam 46 may be an integral part of the pattern formed on the surface when the article 10 is applied to the surface. For example, seams may be involved in forming a pattern, such as when each article is formed as a square or a block and a number of blocks are applied to the surface in a tile pattern. As another example, article 10 may have a pattern of vertical stripes that receive as vertical features seams created between juxtaposed articles 10.

Various methods of forming the article 10 are US Provisional Application No. 60 / 343,146, filed Dec. 20, 2001, entitled Agent Control Number 8817P, entitled “Articles and Methods for Applying Color on Surfaces”. US Provisional Patent Application No. 60 / 380,225, filed May 13, 2002, entitled Agent Control Number 8817P2, and entitled "Goods and Methods for Applying Color on Surface," and Agent Control Number 8817P3. US Provisional Patent Application No. 60 / 380,205, filed May 13, 2002 and entitled "Articles and Methods for Applying Color on Surface," each of which is incorporated herein by reference. Included. In general, the various additives and structures described herein may optionally be provided to the dry colorant component and / or adhesive during the manufacturing process of producing the article 10.

In view of the above, it will be apparent that the article according to the invention can be formed by various methods and techniques. One such method is disclosed herein for illustrative purposes only. More specifically, referring to FIG. 16, a small lab scale semi-automatic process is shown. A releasable liner 100 is provided in the form of a roll that is unwound to run through the assembly 102 via rollers 104, 106, 108, 110, 112, 114 and wound onto the roll 118. 116 is formed. As explained in more detail below, the cutout portion 120 is directed to the roll 122. The release liner 100 is drawn out as a web 101 through the assembly by a combination of the rolls 118, 122 and the conveyor 124, for example a vacuum conveyor. Suitable vacuum conveyors may include a continuous conveyor belt having two pulleys with an array of spaced apertures exposed in the vacuum chamber immediately below. Negative pressure (vacuum) is produced by the forced air blower. As the belt passes over the chamber, negative pressure is created in each hole, so that the release liner 100 is securely retained in the belt as it passes over the belt. This effect helps to prevent wrinkles in release liner 100 when the applied color component is dried. The vacuum conveyor belt speed may be matched with the speed of the drive rolls 118, 122 driven by the driver 119. The axis of the roller 126 from which the release liner 100 is supplied is connected with a friction clutch 128 that may be adjusted to obtain sufficient tension in the web 101 for smooth running through the process. A pipe guide unit 130 may be provided to detect web travel through the assembly.

Color components, such as wet paint, are applied to the web 101 of the release liner adjacent the roller 106 using the applicator 132. Paint or other color components may be aqueous or solvent type as desired. In one embodiment, applicator 132 is a # 50 wire winding rod that may be held against roller 106 by spring tension or the like such that web 101 passes between roller 106 and applicator 132. rod). Color components such as paint are introduced by the manifold 134 upstream of the wire winding rod applicator 132. The manifold is supplied by the pipe 136 from a peristaltic pump 138 which withdraws the wet pate from the reservoir 140. To form a sheet of dry color component, the paint is dried on the web 101 by the use of a dryer, for example as the web passes over the vacuum conveyor 124. In the embodiment of FIG. 16, the dryer includes two infrared heaters 142 assisted by a forced ambient air duct 144. The air duct 144 may conveniently blow the exhaust from the vacuum conveyor 124. Those skilled in the art will readily appreciate that solvent or other carriers removed during the drying process may be captured and recycled as desired. Thus, a dry color component sheet is formed on the release liner web.

The adhesive is then applied to the dry color component sheet on the surface opposite the release liner. For example, in the assembly 102 of FIG. 16, the adhesive may be applied to the sheet of dry color component on the web 101 at the roller 108 by an applicator 148, which may include, for example, a # 20 wire winding rod. Applied to the surface. The wire winding rod applicator 148 may be held against the roller 108 by spring tension or the like such that the web 101 passes between the roller and the applicator. Liquid adhesive is introduced by the manifold 146 upstream of the wire winding rod applicator 148. Manifold 146 is supplied by tubing 150 from metering pump 152 to withdraw liquid adhesive from reservoir 154. Liquid adhesive in reservoir 154 is continuously stirred by mixer 156. With the adhesive applied on top, the web 101 moves back and forth in the machine direction back and forth on the slider plate 160 to give a texture to the liquid adhesive applied to the sheet of dry color component on the web 101. Drive up to (oscillating fabric covered roller, 158). The textured adhesive may allow the article to be more easily repositioned prior to permanent bonding. The adhesive is then dried, for example by passing the web 101 under the infrared heater 162 at the roller 110.

In a preferred embodiment, the web 101 runs through the rollers 112, 114, one of which is preferably in the form of a rotary cutting knife. In a more specific embodiment, the roller 114 includes two rotary cutting knives arranged adjacent to the edge of the web to cut the edge of the web to provide a uniform edge to the final article. In another embodiment, the roller 114 may comprise a plurality of sets of rotary cutting knives arranged to cut the web into two or more strips to provide a small sized article suitable for applying color to a small sized area as described above. Include. Then, while the final article 116 is wound on the roll 118, the cut edge 120 is wound on the roll 122. As mentioned above, the described assembly 102 and manufacturing process are merely exemplary, and variations thereof will be apparent to those skilled in the art. For example, release agents in the form of coatings or layers may be provided in the process. In addition, the dry color component sheet may be provided in the final article without a release liner. For example, the dry color component sheet may be formed on the processing web or forming belt and then separated from the processing web or forming belt before being stored in roll or sheet form.

In an alternative embodiment, the article according to the invention may be formed using a modification of the above-described process, in which two release liner webs are employed. For example, the top coating composition for forming the top coating layer may be applied to the release liner web by techniques such as reverse roll, extrusion coating and the like and dried on the release liner web by, for example, heat. The color composition can then be applied to the dried top coating layer, for example by reverse rolls, gravure coating, printing or similar techniques, and then dried by heat. The adhesive is then applied to the second release liner web, and then the release liner-top coating-dry color component member and the adhesive-release liner member are laminated in a dry face-to-adhesive relationship. Heat may be provided by any suitable means including convection or radiation, such as infrared or ultraviolet light, throughout this process. One skilled in the art may also be used to provide an article comprising a single release liner by simply removing the second release liner from the adhesive once the release liner-top coating-dry color component member and the adhesive-release liner member are assembled. Will understand.

Additional or alternative apparatus and / or processing steps will be apparent to those skilled in the art by the description herein and are within the scope of the present invention. For example, the color component or adhesive may be applied in a single layer or multiple layers using a variety of known application techniques including extrusion, spraying, printing, reverse rolls, gravure coating, roll application, and other techniques known in the art. have. It is understood that such application may provide a printed pattern on the sheet. The layers may have the same properties, or different layers may be employed to combine various properties such as color, intensity, opacity, and the like. The aforementioned barrier agent may be applied to the adhesive surface and / or mixed with the adhesive. Heating can be provided by infrared, convection or radiation devices or other techniques known in the art.

The color composition may comprise additional compositions such as light diffusing materials, fine particles, particulates or fluidization control additives of the present invention. Texture formation for providing three-dimensional topography by incorporating a stamp or embossing roller into the manufacturing process described herein may be provided on or in one or more layers of the article. In addition, the manufacturing process described herein may include a cutting mechanism for contouring or shaping at least one of the outer peripheral edges of the dry color component sheet. The manufacturing process may also include structures for thinning the edges in accordance with the principles of the present invention.

All documents cited in the Detailed Description of the Invention are hereby incorporated by reference in their entirety, and citation of any arbitrary document is not to be construed as an admission that this document is prior art with respect to the present invention.

While particular embodiments of the invention have been illustrated and described, it will be apparent to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. Accordingly, all such modifications and variations that fall within the scope of the invention are intended to be included in the appended claims.

Claims (19)

An article for applying color on a surface, A sheet of dry colorant having an outer circumferential edge, an edge adjacent to the outer circumferential edge, a sheet front side and a sheet back side opposite the sheet front side; An adhesive on the back of the sheet for adhering the sheet to a surface; The sheet and the adhesive have a thickness of less than about 84 micrometers (3.3 mils), and at least the edges of the sheet reduce visible visibility of the seams produced when the article overlaps with the juxtaposed second article. Is done; The sheet front surface includes a print pattern having a plurality of image elements and a plurality of contrast areas, each of the image elements acting to reduce the visible perception of the seam when the article overlaps a juxtaposed second article In such a way that it is spaced apart from an adjacent image element of said image elements by a corresponding contrast area of said contrast areas; Adjacent ones of said image elements having a spatial distribution of an amorphous pattern. The article of claim 1, wherein the sheet comprises a rheology-modifying additive that acts to selectively coalesce the dry colorant material forming the edges. The method of claim 1, wherein the dry colorant forming the sheet is textured with three-dimensional topography having a plurality of protrusions and a plurality of depressions, wherein adjacent ones of the protrusions are corresponding depressions of the plurality of depressions. Goods separated by. The article of claim 1, wherein the dry colorant forming the edge has a smaller thickness than the dry colorant forming another portion of the sheet. The article of claim 1, wherein the dry colorant or adhesive comprises a structural component adapted to at least partially collapse upon application of a compression pressure directed generally inwardly towards the surface. The method of claim 1, wherein the outer edge is contoured in a nonlinear pattern of repeating elements; Wherein the transition between adjacent pairs of repeating elements is a smooth curve. The article of claim 1, wherein the print pattern is formed of a plurality of pixels. The article of claim 1, wherein at least the edge of the article has an opacity index in the range of about 0.95 to 1.0 as measured according to ASTM D2805. The article of claim 1, wherein the sheet is adapted to diffusely reflect incident visible light. The article of claim 1, wherein the sheet comprises a pearlescent material having a particle size distribution capable of producing a pearlescent reflective reflective effect. The article of claim 1, wherein the outer circumferential edge is rounded. An article for applying color on a surface, A dry colorant sheet having an outer circumferential edge, an edge adjacent to the outer circumferential edge, a sheet front side and a sheet back side opposite the sheet front side; An adhesive on the back of the sheet for adhering the sheet to a surface; The edge may be juxtaposed in a non-overlapping manner with the edge of the juxtaposed second article to provide a gap therebetween; The sheet and the adhesive have a thickness of less than about 84 μm (3.3 mil); And the gap is associated with a filler adapted to reduce the visible perception of the gap. In a kit for applying color on a surface, A dry colorant sheet having an outer circumferential edge, an edge adjacent to the outer circumferential edge, a sheet front side and a sheet back side opposite the sheet front side; An adhesive on the back of the sheet for adhering the sheet to a surface; Initiators acting to enhance visible decline in cognition; An authorization device; At least the edge of the sheet is adapted to reduce the visible perception of the seam produced when the article overlaps the juxtaposed second article; Wherein said sheet and said adhesive have a thickness of less than about 84 μm (3.3 mil). 14. The kit of claim 13, wherein the edge comprises a fluidization control additive that acts to selectively coalesce the dry colorant material forming the edge. In the method for applying a dry colorant to the surface, Adhesively fixing to the surface a first article comprising a dry colorant sheet; Adhesively fixing the second article comprising the dry colorant sheet to the surface in juxtaposition with the first article; Each of the first and second articles has a thickness of less than about 84 μm (3.3 mil); Each of the first and second articles includes overlapping respective edges to provide an overlapped thickness; The method further comprises reducing the visible perception of the seam created for the overlap of the first and second articles. The method of claim 15, wherein at least an edge of at least one of the sheets of the first and second articles comprises a fluidization control additive that selectively acts to coalesce the dry colorant that forms the edge when exposed to the initiator, Said reducing step further comprises using an initiator at the edge of at least one of the first and second sheets to activate the fluidization adjustment additive for coalescing the dry colorant material forming the edge. The apparatus of claim 15, wherein at least an edge of at least one of the sheets of the first and second articles comprises a collapsible structure that is susceptible to selectively collapse when a compressive pressure of sufficient magnitude is applied in a generally directed direction toward the surface; And the reducing step further comprises applying a compressive pressure directed generally towards the surface to the overlapping edge such that the collapsible structure at least partially collapses. A method of making an article for applying color to a surface, Preparing a dry colorant sheet having an edge; Bonding the adhesive to the dry colorant sheet; Modifying the sheet to reduce the visible perception of the seam produced when the sheet is applied to the surface with the edge in an overlapping relationship with the edge of another sheet; The dry color sheet and adhesive had a thickness of less than about 84 μm (3.3 mil); The modifying step includes printing a pattern on the sheet front of the sheet, the pattern having discrete image elements spaced apart to serve to reduce the visible perception of the seam; Adjacent image elements of the image elements having a spatial distribution of an amorphous pattern. 19. The method of claim 18, wherein the modifying comprises stamping the sheet into a three-dimensional texture having surface features extending above and below the plane comprising the sheet, the texture reducing the visible perception of the seam. How had it been.

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